Method and device for controlling jet flow intensity for a spa

ABSTRACT

A method and device for controlling the intensity of flow of water leaving a single speed water pump and entering a spa tub. A single speed water pump is connected to a spa tub via a pump suction pipe and a pump outlet pipe. The single speed water pump has its suction connected to the spa tub and sucks water out of the spa tub via the pump suction pipe. A controller is electrically connected to at least one air valve and the air valve is connected to the pump suction pipe. The controller opens the air valve to allow air into the pump suction. Air from the air valve mixes with water pumped from the tub to create an air/water mixture. The air water mixture is pumped back into the spa tub via the pump outlet pipe. The intensity of the flow of the air water mixture back into the spa tub depends upon the amount of air allowed into the air/water mixture via the air valve. Preferably, the controller is programmed with programming instructions to vary the intensity of the flow of the air/water mixture back into the spa tub. Also, several air valves may be utilized to provide a range of air flows.

[0001] The present invention relates to spas, and in particular, towater pumps for spas.

BACKGROUND OF THE INVENTION

[0002] A spa (also commonly known as a “hot tub”) is a therapeutic bathin which all or part of a person's body is exposed to hot water, usuallywith forceful whirling currents. When located indoors and equipped withfill and drain features like a bathtub, the spa is typically referred toas a “whirlpool bath”. Typically, the spa's hot water is generated whenwater contacts a heating element in a water circulating heating pipesystem.

[0003]FIG. 1 shows a prior art hot tub spa 1. Spa controller 52 isprogrammed to control the spa's components, such as the spa's waterpumps 1P and 2P, air blower 3, ozonator 7, stereo 1A, and light 1L. Innormal operation, water from drains 13A and 13B is pumped by water pump2P back into tub 2 and by pump 1P through heater 5A where it is heatedby heating element 5B. The heated water then leaves heater 5A and entersspa tub 2 through jets 11. Water leaves spa tub 2 through drains 13A and13B and the cycle is repeated.

Varying the Intensity of the Water Stream Leaving the Jets

[0004] The therapeutic effect provided by the variation of the intensityof the water stream leaving jets 11 is a desirable feature for a spa. Inthe prior art, variation of the intensity of the water stream isachieved by utilization of a variety of different prior art methods. Forexample, the orifice of the jet itself can be adjustable so that flow ofwater can be restricted thereby decreasing its flow intensity. Also,diverter valves can be used to spread the flow from the water pump overa greater or lesser number of jets to change the flow, and consequentlythe intensity, through a particular jet or group of jets. Or a variablespeed water pump can be utilized to control the intensity of the flow.For example, as the pump is slowed down, the intensity of flow through ajet will decrease. Likewise, as the speed of the pump is increased, theintensity of the flow through a jet will increase.

Variable Speed Pumps for Spas

[0005] The variable speed pump depends on the use of a universalvariable speed motor to vary the speed of the pump. An increase ofamperage to the motor increases the RPM of the motor. Likewise,decreasing the amperage decreases the motor's RPM. Adjusting the RPM ofthe motor naturally adjusts the flow rate of the pump and the intensityof the water leaving the jets.

[0006] There are several disadvantages associated with the utilizationof a prior art variable speed pump for a spa. Some of thesedisadvantages are: 1) pump size, 2) excessive noise, and 3) high cost.

Pump Size

[0007] Available variable speed pumps tend to be built to include auniversal motor designed for the vacuum cleaner industry. Therefore, thechoices of motor size and power are limited to what is available for thelarger, more popular, vacuum cleaner market. This means, typically, thatthe current variable speed pumps are only commonly used for indoorwhirlpool bath applications and not in the larger outdoor portable spas.It is more desirable to have a larger pump for an outdoor portable spabecause the outdoor portable spa usually contains a larger volume ofwater than a whirlpool bath.

Excessive Noise

[0008] Another disadvantage associated with prior art variable speedpumps for spas is that the universal variable speed motor is very loud.

High Cost

[0009] Variable speed pumps are expensive. For example a typicalvariable speed pump for an indoor whirlpool bath can cost approximately$120.00. In contrast a similarly sized pump having a single speedinduction motor and can cost approximately $50.00 (less than half theprice of the variable speed pump).

Cavitation

[0010] Cavitation is a well known phenomena associated with fluid pumps.Cavitation can occur in a hydraulic system as a result of low fluidlevels that draw air into the system, producing tiny bubbles that expandexplosively at the pump outlet, causing reduction in pump deliverycapacity, metal erosion and eventual pump destruction.

Purposeful Introduction of Air into a Pump to Vary Pump DeliveryCapacity

[0011] Air drawn into the pump system through cavitation is potentiallyvery harmful to a pump and is generally to be avoided. However, it isknown that air can purposely be added to a fluid pump suction in amanner that will not cause damage to the pump. It is known to add air tothe suction of a single speed pump to vary the delivery capacity of thepump.

[0012]FIG. 5 shows a prior art spa whirlpool bath 130 having manuallycontrolled air valve 120. GG Industries with offices in Valencia, Calif.currently manufactures manually controlled air valves (part nos. 99126and 99128) similar to air valve 120 for utilization in spas.

[0013] Air valve 120 has an orifice. The amount of air that is allowedto enter the orifice is controlled by the turning of knob 121. Forexample, when knob 121 is fully turned in the clockwise direction, theorifice is completely covered and no air enters air line 122. However,as knob 121 is turned counterclockwise, the orifice is graduallyrevealed. When knob 121 is turned fully counterclockwise, the orifice iscompletely uncovered and the maximum amount of air is allowed into airline 122.

[0014] The delivery capacity of single speed induction motor pump 124varies as air is added to the suction of pump 124 via air line 122. Thegreater the amount of air added, the lower the delivery capacity of pump124. By varying the delivery capacity of pump 124, the user varies theintensity of the flow leaving jets 123.

[0015] What is needed is a better way to control the intensity of flowof water entering the spa tub via the spa jets.

SUMMARY OF THE INVENTION

[0016] The present invention provides a method and device forcontrolling the intensity of flow of water leaving a single speed waterpump and entering a spa tub. A single speed water pump is connected to aspa tub via a pump suction pipe and a pump outlet pipe. The single speedwater pump has its suction connected to the spa tub and sucks water outof the spa tub via the pump suction pipe. A controller is electricallyconnected to at least one air valve and the air valve is connected tothe pump suction pipe. The controller opens the air valve to allow airinto the pump suction. Air from the air valve mixes with water pumpedfrom the tub to create an air/water mixture. The air water mixture ispumped back into the spa tub via the pump outlet pipe. The intensity ofthe flow of the air water mixture back into the spa tub depends upon theamount of air allowed into the air/water mixture via the air valve.Preferably, the controller is programmed with programming instructionsto vary the intensity of the flow of the air/water mixture back into thespa tub. Also, several air valves may be utilized to provide a range ofair flows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 shows a prior art spa.

[0018]FIG. 2 shows a side view of a preferred embodiment of the presentinvention.

[0019]FIG. 3 shows a top view of a preferred embodiment of the presentinvention.

[0020]FIG. 4 shows another preferred embodiment of the presentinvention.

[0021]FIG. 5 shows a prior art whirlpool bath.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] A detailed description of a preferred embodiment of the presentinvention may be described by reference to FIGS. 2-4. In the presentinvention, the intensity of the flow leaving jets 71 (FIGS. 2 and 3) iscontrolled by controller 75. Controller 75 can be pre-programmed at thefactory, it can be programmed directly by the user utilizing keypad 74or the intensity of the flow leaving jets 71 can be controlled by theuser in a direct fashion via controller 75 by the manipulation of keypad74.

First Preferred Embodiment

[0023]FIG. 2 shows a side view and FIG. 3 shows a top view of the firstpreferred embodiment of the present invention. Spa 61 is a whirlpoolbath. Prior to entering spa 61, the user fills tub 62 by turning handvalve 63. Water (set to a temperature preferred by the user) then exitsfaucet 64 and enters tub 62. When the user is finished relaxing in spa61, he may remove stopper 65 and water will be drained out throughdrainpipe 66.

Operation of the First Preferred Embodiment

[0024] While spa 61 is in operation, pump 69 pumps the water in tub 62into pipe 68. Pump 69 sucks the water from pipe 68 into pipe 70 and thenforces it out through jets 71 back into tub 62. Preferably, pump 69 is asingle speed induction motor pump.

Controlling the Speed and Intensity of the Water Leaving the Jets

[0025] Because pump 69 is a single speed induction motor pump, the speedof the pump's motor is constant and is not varied. However, theintensity and flow rate of the water (in gallons per minute) flowingthrough pipe 70 and out through jets 71 can be varied by introducing airinto pump suction pipe 68. The introduction of air into the suction ofpump 69 causes pump 69 to operate less efficiently. Therefore, when airis introduced into pipe 68, water leaving pump 69 does so at a lowerspeed and with reduced intensity.

[0026] Normally, as stated in the ‘Background of the Invention’ section,air added to a pump through cavitation can cause damage to a pump.However, when done in a controlled fashion, the harmful effects addingair to a pump can be greatly diminished and even eliminated.

Introduction of Air into the Pump

[0027] Keypad 74 is electrically connected to controller 75. Controller75 is also electrically connected to air valves 72 and 73. A usersitting in spa 61 can manipulate keypad 74. For example, after pressingkeys on keypad 74, controller 75 will send corresponding electricalsignals to either “open” or “shut” air valves 72 and 73. Preferably, airvalves 72 and 73 are solenoid air valves manufactured by EvolutionaryConcepts, Inc. with offices in San Dimas, Calif. Air valve 72 ispreferably part no. 620-220 and has a 0.047 inch orifice and air valve73 is preferably part no. 621-220 and has a 0.062 inch orifice. Throughexperimentation, Applicant has concluded that orifices of 0.047 inch and0.062 inch are preferred and result in no noticeable damage to the pump.

[0028] Water flowing through pipe 68 creates a drop in pressure throughpipe 68. Hence, after the opening of air valves 72 and/or 73, the movingwater draws air into pipe 68 through pipe 76 via the venturi effect (asthe speed of a moving fluid (liquid or gas) increases, the pressurewithin that fluid decreases).

[0029] A mixture of air and water enters pump 69. The greater the amountof air that is present in the air/water mixture, the less efficient theoperation of pump 69. For example, when both air valves 72 and 73 (FIG.3) are closed, pump 69 operates at maximum efficiency and the speed ofthe water leaving jets 71 is at its highest. Likewise when both valves72 and 73 are open, pump 69 is operating at its lowest efficiency andspeed of the water leaving jets 71 is at its lowest. Table 1 summarizesthe relationship of the speed of the water leaving the jets and theposition of solenoid air valves 72 and 73. TABLE 1 Position of Valve 72Position of Valve 73 Speed of Water Leaving Jets (orifice = .047 inch)(orifice = .062 inch) High Speed Closed Closed Med-High Speed OpenClosed Med-Low Speed Closed Open Low Speed Open Open

Second Preferred Embodiment

[0030] In the second preferred embodiment, controller 75 has beenpre-programmed at the factory so that the flow of the water leaving jets71 creates a soothing wave effect. For example, controller 75 isprogrammed to automatically open and shut valves 72 and 73 so that thespeed of the water exiting jets 71 varies from High Speed to Med-HighSpeed to Med-Low Speed to Low Speed in a repetitive manner until theuser turns pump 69 off. Table 2 summarizes a preferred sequence in whichevery 12 seconds the cycle is repeated until the user turns pump 69 off.TABLE 2 Speed of Water Position of Valve 72 Position of Valve 73 TimeLeaving Jets (orifice = .047 inch) (orifice = .062 inch) (secs) HighSpeed Closed Closed T = 0-3 secs Med-High Open Closed T = 3-6 secs SpeedMed-Low Closed Open T = 6-9 secs Speed Low Speed Open Open T = 9-12secs*

Third Preferred Embodiment

[0031] The third preferred embodiment is similar to the second preferredembodiment, except that a user can personally program controller 75 toswitch between the speed settings in a fashion according to the specificpreferences of the user. For example, in one preferred embodiment theuser may program controller 75 so that water leaving jets is at a HighSpeed for 1 minute, to be followed immediately by Low Speed for 10seconds, then Med-Low Speed for 10 seconds, and then Med-High Speed for10 seconds. The user may also program this cycle to repeat for aspecific amount of time, or alternatively he can have it repeatindefinitely until he turns pump 69 off.

Fourth Preferred Embodiment

[0032]FIG. 4 shows a fourth preferred embodiment of the presentinvention in which the present invention is utilized with a portablespa. Spa 81 is a portable spa similar to the portable spa shown in FIG.1 and described above in the Background section, with the exception thatspa 81 utilizes the introduction of air into pipes 93 and 94 to controlthe speed and intensity of water leaving pumps 91 and 92, respectively.Air valves 72A and 73A and air valves 72B and 73B are controlled by spacontroller 52. Preferably a user sitting in tub 2 manipulates keypad 8to control valves 72A, 73A, 72B, and 73B in a fashion similar to thatdescribed above in reference to the other preferred embodiments. Airentering valves 72A and 73A is drawn into pipe 93 via the venturieffect, causing the speed and intensity of water leaving pump 91 todiminish. Likewise, air entering valves 72B and 73B is drawn into pipe94 via the venturi effect, causing the speed and intensity of waterleaving pump 92 to diminish. As with the second preferred embodiment,the user can control which air valves to open or shut by pressing keypad8. Or, as was the case with the second and third preferred embodiments,spa controller 52 can be programmed to open or shut the air valves is acyclic sequence.

[0033] Although the above-preferred embodiments have been described withspecificity, persons skilled in this art will recognize that manychanges to the specific embodiments disclosed above could be madewithout departing from the spirit of the invention. For example,although it was stated that through experimentation Applicant hasconcluded that orifices of 0.047 inch and 0.062 inch are preferred,other orifice sizes could be utilized as well. Also, although thepreferred embodiments disclosed two air valves 72 and 73, it would alsobe possible to utilize just one air valve or more than two air valves(for example, three or four air valves). Also, although the abovepreferred embodiments disclosed air valves that could be either fully“open” or fully “closed”, it is possible to utilize an air valve thatcan gradually be opened or closed. This air valve would be moreexpensive, but would give more precise control to the amount of airallowed into the pump suction. Therefore, the attached claims and theirlegal equivalents should determine the scope of the invention.

What is claimed is:
 1. A spa, comprising: A. a spa tub for holdingwater, B. a single speed water pump defining a pump suction and a pumpoutlet, C. a pump suction pipe connecting said spa tub and to said pumpsuction, D. a pump outlet pipe connecting said pump outlet to said spatub, E. at least one air valve for allowing air into said pump suctionpipe, and F. a controller electrically connected to said at least oneair valve, wherein said controller is capable of opening and shuttingsaid at least one air valve to allow air into said pump suction pipe,wherein the air passing through said at least one air valve mixes withthe water in said pump suction pipe to form an air/water mixture,wherein said air/water mixture is pumped via said single speed waterpump back into said spa tub via said pump outlet pipe, wherein theintensity of flow of said air/water mixture back into said spa tubdepends upon the amount of air allowed into said air/water mixture viasaid at least one air valve.
 2. The spa as in claim 1, wherein said spais a whirlpool bath.
 3. The spa as in claim 1, wherein said spa is aportable spa.
 4. The spa as in claim 1 further comprising an air lineconnected between said at least one air valve and said pump suctionpipe, wherein said at least one air valve allows air into said pumpsuction pipe via said air line.
 5. The spa as in claim 1, furthercomprising a keypad electrically connected to said controller, whereinsaid keypad is user controllable to open and shut said at least one airvalve.
 6. The spa as in claim 5, wherein programming instructions forsaid controller are entered via said keypad, wherein said programminginstructions control said opening and shutting of said at least one airvalve, wherein said intensity of flow of said air/water mixture backinto said spa tub varies according to said programming instructions. 7.The spa as in claim 1, wherein said controller is programmed withprogramming instructions to control said opening and shutting of said atleast one air valve, wherein said intensity of flow of said air/watermixture back into said spa tub varies according to said programminginstructions.
 8. The spa as in claim 1, wherein said at least one airvalve is a plurality of air valves.
 9. A spa, comprising: A. a spa tubmeans for holding water, B. a single speed water pump means defining apump suction and a pump outlet, C. a pump suction pipe means connectingsaid spa tub means and to said pump suction, D. a pump outlet pipe meansconnecting said pump outlet to said spa tub means, E. at least one airvalve means for allowing air into said pump suction pipe means, and F. acontroller means electrically connected to said at least one air valvemeans, wherein said controller means is capable of opening and shuttingsaid at least one air valve means to allow air into said pump suctionpipe means, wherein the air passing through said at least one air valvemeans mixes with the water in said pump suction pipe means to form anair/water mixture, wherein said air/water mixture is pumped via saidsingle speed water pump means back into said spa tub means via said pumpoutlet pipe means, wherein the intensity of flow of said air/watermixture back into said spa tub means depends upon the amount of airallowed into said air/water mixture via said at least one air valvemeans.
 10. The spa as in claim 9, wherein said spa is a whirlpool bath.11. The spa as in claim 9, wherein said spa is a portable spa.
 12. Thespa as in claim 9 further comprising an air line means connected betweensaid at least one air valve means and said pump suction pipe means,wherein said at least one air valve means allows air into said pumpsuction pipe means via said air line means.
 13. The spa as in claim 9,further comprising a keypad means electrically connected to saidcontroller means, wherein said keypad means is user controllable to openand shut said at least one air valve means.
 14. The spa as in claim 13,wherein programming instructions for said controller means are enteredvia said keypad means, wherein said programming instructions controlsaid opening and shutting of said at least one air valve means, whereinsaid intensity of flow of said air/water mixture back into said spa tubmeans varies according to said programming instructions.
 15. The spa asin claim 9, wherein said controller means is programmed with programminginstructions to control said opening and shutting of said at least oneair valve means, wherein said intensity of flow of said air/watermixture back into said spa tub means varies according to saidprogramming instructions.
 16. The spa as in claim 9 wherein said atleast one air valve means is a plurality of air valve means.
 17. Amethod for controlling the intensity of flow of water leaving a singlespeed water pump and entering a spa tub, comprising the steps of: A.connecting a single speed water pump to a spa tub holding water via apump suction pipe and a pump outlet pipe, B. utilizing said single speedwater pump to pump water out of said spa tub via said pump suction pipe,C. electrically connecting a controller to at least one air valve, D.utilizing said controller to open said at least one air valve to allowair into said pump suction pipe, wherein said air mixes with said waterpumped out of said spa tub to create an air/water mixture, and E.utilizing said single speed water pump to pump said air/water mixtureback into said spa tub via a pump outlet pipe, wherein the intensity offlow of said air/water mixture depends upon the amount of air allowedinto said air/water mixture via said at least one air valve.
 18. Themethod as in claim 17, wherein said spa is a whirlpool bath.
 19. Themethod as in claim 17, wherein said spa is a portable spa.
 20. Themethod as in claim 17 further comprising the step of connecting an airline between said at least one air valve and said pump suction pipe,wherein said at least one air valve allows air into said pump suctionpipe via said air line.
 21. The method as in claim 17, furthercomprising the step of electrically connecting a keypad to saidcontroller, wherein said keypad is user controllable to open and shutsaid at least one air valve.
 22. The method as in claim 21, furthercomprising the step of entering programming instructions for saidcontroller at said keypad, wherein said programming instructions controlsaid opening and shutting of said at least one air valve, wherein saidintensity of flow of said air/water mixture back into said spa tubvaries according to said programming instructions.
 23. The method as inclaim 17, further comprising the step of programming said controllerwith programming instructions to control said opening and shutting ofsaid at least one air valve, wherein said intensity of flow of saidair/water mixture back into said spa tub varies according to saidprogramming instructions.
 24. The method as in claim 17, wherein said atleast one air valve is a plurality of air valves.